CONFIDENTIAL CKB 30103

UNIVERSITI KUALA LUMPUR

MALAYSIAN INSTITUTE OF CHEMICAL
& BIOENGINEERING TECHNOLOGY

BACHELOR IN CHEMICAL ENGINEERING TECHNOLOGY

TEST 1 ANSWER
JULY SEMESTER 2017 SCHEME

COURSE CODE : CKB 30203 (COHORT JAN 2017)

: CKB 30103 (COHORT SEPT 2016 & BEFORE)

COURSE : INDUSTRIAL SAFETY & HEALTH

DURATION : ONE and HALF HOUR (1:30 minutes)

NAME : ………………………………

ID NUMBER : ……………………………….

GROUP : CKB 30103 L01 T1 / T2 /T3 / T4 / T5

CKB 30203 L01 T1 / T2 / T3 / T4

LECTURER IN – CHARGE : NOR AINI BUROK

: SYAHIDI FADZLI ALFAN
OF TUTORIAL : NAJUA DELAILA TUMIN
: AIMAN NAZMI ROSLI
(please circle one) : INDOK NURUL HASYIMAH MOHD AMIN
: NUGROHO DEWAYANTO

INSTRUCTIONS TO CANDIDATES:

1. Answer ALL questions in the ANSWER SHEET provided

2. Show clearly steps taken in arriving at the solution and indicate ALL assumptions clearly

THIS QUESTION SHEET CONSISTS OF 7 PRINTED PAGES INCLUDING THIS PAGE.

ATTENTION: DO NOT OPEN THIS BOOKLET UNTIL PERMISSION IS GIVEN TO DO SO.

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CONFIDENTIAL CKB 30103

1. Explain the following hazard identification method with its example:

“Review of documentation: legal statutory” (4 marks)

Answer:
Key points- review Law such Act 514 (OSHA) and its regulation ……..1M
and / or Review Act 139 (FMA)……………………………1M
Example in OSHA is CIMAH regulation , Prohibition of Use of Substance Order, 1999 –
to control usage asbestos ……………………….1M
Example in FMA,1967 (ACT 139) : Noise regulation , Lead regulation……..1M

2. Provide the definition of common term in safety.

a) Hazard (2 marks)
Answer
“Any sources, situations or acts with a potential for harm…….0.5M
in terms of human injury or ill health, damage to property, damage to the
workplace, environment, ……………………1M
or combination of these”………………….0.5M

3. A firm has 2000 staff (employees work a regular 40-hour work-week). During the year there
are seven first-aid cases, three medical treatment injuries, an accident in which an injured
employee was required to work one week in restricted work activity, a work-related illness in
which the employee lost one week of work, a work-related illness in which the employee lost
six weeks of work, and a fatality resulting from electrocution

Calculate the following:-

a) OSHA incidence rate (4 marks)

b) Fatality rate (4 marks)

c) Lost Time Injury Rate (4 marks)

ANSWER:
Analyzing the question:
seven first-aid cases, - NON RECORDABLE.
three medical treatment injuries, - 3 cases OCCUPATIONAL INJURY
an accident in which an injured employee was required to work one week in restricted work
activity – 1 case Non Fatal without lost work day.

a work-related illness in which the employee lost one week of work, - 1 case
OCCUPATIONAL ILLNESS; with LOST WORK= 7 DAYS.
a work-related illness in which the employee lost six weeks of work, - 1 case
OCCUPATIONAL ILLNESS; with LOST WORK DAYS = 42 DAYS.
and a fatality resulting from electrocution - 1 case FATALITY.

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CONFIDENTIAL CKB 30103
Calculate the following:-

a) OSHA incidence rate (4 marks)

OSHA IR = Number of injuries & illness x 200,000

--------------------------------------------------------------------------------------
Total number of hours worked by all employees during period covered.

Recordable cases = 5 x 200,000

-------------------- …………………1.0M
2000 x 50 x 40

= 1,000,000
-----------------
4,000,000

= 0.25 …………1.5 M

 Conclusion: For every 2000 employees of this organization, the rate that an employee involved
in a recordable injury or illness is 0.25 ………….1.5M

(b)Fatality rate (4 marks)

Fatality Rate= Number of fatalities per year

----------------------------------------------------------------------
Total number of people (per year) in applicable population

Number of fatality= 1;

= 1 / 2000 ………………1.0 M

= 0.005 ………….1.5 M

 Conclusion: For every 2000 employees of this organization, the rate that an employee involved
in a fatal accident is 0.005 ………….1.5M

(c)Lost Time Injury Rate (4 marks)

Lost Time Injury rate = Number of lost time injury (hrs) x 200,000
---------------------------------------------------------------------------------
Total number of hours worked by all employees during period covered.

No of Lost time injury = 7 + 42 days x 8 hrs = 343 hrs ………0.5M

= 343 x 200,000
-------------------- ………………0.5M
2000 x 50 x 40

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CONFIDENTIAL CKB 30103
= 68600000 / 4,000,000

= 17.15 …….1.5M
.
 Conclusion: For every 2000 employees, 17.15 hours have been lost because of a
work related injury or illness or fatalities……….1.5M

4. Write the most suitable control measure according to the hierarchy of control for the
following case:

(6 marks)

No Description
1 Ahmad has been working in a bakery for 10 years. He was diagnosed
to have occupational asthma. He was given mask by his employer; to
be worn during working.

ANSWER:Minimization and prevention of the hazard (flour

dust)……1M
Through Substituting the method cleaning from sweeping to
vacuuming…..1M and/ or through Engineering control -
isolating/enclosure the source of hazard…………1M
[The answer cannot be PPE, because has been given by his employer]

2 Denon is a packaging manufacturer. In August 2017, 2 new A4 size

paper cutting machines arrived at the factory without a safety features
to control the hazard.

ANSWER:Minimization and prevention of the hazard (sharp

object/cutting hazard)……1M
Through Engineering control - isolating/enclosure the source of
hazard…………1M by installing guard at the source of
hazard…………1M

Other answer such as:

Administration Control by giving training ……1 mark only (Less
appropriate)
PPE control by wearing PPE ……..1 mark only(Less appropriate)

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CONFIDENTIAL CKB 30103
5. The Excell Sdn Bhd is metal stamping company. It has 250 staff. The following is the
details of accident statistic for year 2015. Evaluate the risk assessment from the following
data.

OCCUPATIONAL ACCIDENT CASES:

A Accident related fatalities No of death 1
(death)
B Accident with lost workdays Total accident cases with days away 2
from work
C Accident with lost workdays Total number of days away 6031
from work
D Accident without lost workdays Total accident cases without 1
lost workdays
E Total of number of accidents 3

(4 marks)

Answer:

Total man-hours worked in Year 2015 (Round up to the nearest whole number)

Y = 250 x 50 weeks/yr x 5 days/week x 8 hrs/day

= 500,000 ……..1M

Frequency Rate = No. of Accidents (E) x 1,000,000 / Total man-hours worked (Y)

= 3 x 1,000,000 / 500,000

= 6……..1M

Severity Rate = Total workdays lost (C) x 1,000,000 / Total man-hours worked (Y)

= 6031 x 1,000,000 / 500,000

= 12,062……..1M

Risk Assessment = Frequency Rate x Severity Rate

= 6 x 12,062

= 72, 372 …………..1M

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CONFIDENTIAL CKB 30103
6. Consider the continuous process shown BELOW. In this process, the phosphoric acid and
ammonia are mixed, and a non-hazardous product, diammonium phosphate (DAP), results
if the reaction of ammonia is complete. If too little phosphoric acid is added, the reaction is
incomplete, and ammonia is produced. Too little ammonia available to the reactor results in
a safe but undesirable product. The HazOp team is assigned to investigate "Personnel
Hazards from the Reaction"; by using the following deviation:-

a) NO FLOW OF AMMONIA.
b) LESS FLOW OF PHOSPHORIC ACID.
c) MORE AMMONIA IN THE REACTOR.

[Hint:Use HAZOP Worksheet to answer this question] (12 marks)

TOTAL MARK: 40 MARKS

END OF QUESTION

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ANSWER:

Analyzing the question for the following deviation:-

i. NO FLOW OF AMMONIA – Less ammonia in the reactor. Non Hazardous condition,

but resulted of substandard product is produced…0.25M
ii. LESS FLOW OF PHOSPHORIC ACID – A lot of ammonia in the reactor. A
hazardous condition that is hazard to personnel…..0.25M
iii. MORE AMMONIA IN THE REACTOR - A lot of ammonia in the reactor. A
hazardous condition that is hazard to personnel……0.25M
iv. NO FLOW OF AMMONIA – Less ammonia in the reactor. Non Hazardous condition,
but resulted of substandard product is produced…..0.25M
v. LESS FLOW OF PHOSPHORIC ACID – A lot of ammonia in the reactor. A
hazardous condition that is hazard to personnel…..0.25M
vi. MORE AMMONIA IN THE REACTOR - A lot of ammonia in the reactor. A
hazardous condition that is hazard to personnel…..0.25M

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CONFIDENTIAL CKB 30103
Company Name: ABC Technolgy Sdn Bhd
Project Title: XYZ Project Diagram & Node No: Study Node A …..0.25M
Meeting Date: DDMMYYYY Team Name & leader: ABC bin JKL
Parameter study: FLOW & LEVEL……..0.25M

Guide Deviation Causes Consequences Present Recommendation

words Protection

NO NO FLOW OF 1. Run out of stock in Less ammonia in the Flow Set the minimum level of ammonia
AMMONIA TO the storage reactor. indicator….0.5M in the tank…..0.5M
REACTOR tank….0.5M Non Hazardous Set the required flow
2. Valve A is fully condition, but resulted of Level rate……0.5M
closed…..0.5M substandard product is indicator…..0.5M Connect the Level indicator and
produced…..0.5M flow indicator to an alarm
system……0.5M
LESS LESS FLOW OF 1. Partly blockage at the A lot of ammonia in the Flow Set the minimum flow
PHOSPHORIC pipeline from the reactor. A hazardous indicator….0.5M rate……0.5M
ACID phosphoric tank to condition that is hazard Connect the flow indicator to an
reactor….0.5M to personnel…..0.5M Level alarm system…….0.5M
2. Valve B is partly indicator…..0.5M
closed…..0.5M
MORE MORE AMMONIA A lot of ammonia in the Flow indicator Set the required flow rate…0.5M
IN THE REACTOR 1. Valve A is fully reactor. A hazardous ….0.5M Connect the flow indicator to an
opened…..0.5M condition that is hazard alarm system…….0.5M
to personnel…..0.5M.

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CONFIDENTIAL CKB 30103

Appendix 1

1
OSHA* = NUMBER OF INJURIES & ILLNESS X 200,000
TOTAL HOURS WORKED BY ALL EMPLOYEES
DURING PERIOD COVERED
2
8
FAR = (Number of fatalities x 10 )
Total hours worked by all employees
during period covered

3
Fatality rate = (Number of fatalities per year)
Total number of people (per year)
in applicable population